What is the best/easiest way to cut a slot in a 1/4" Brass rod for an e-clip? The slot needs to be about .020" deep and .030" wide. The dimensions are not that critical - I just want to keep something from falling off a stationary shaft. Two slots will be about 1/4" from the end of the rod. One will be about 3" from the end of the rod.
Cutting it on the lathe would be by far the easiest. However you have to have been through the lathe class to use unless otherwise directed.
@Photomancer
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I assume you are using “E” clip in what old farts like me call a “C” clip or something very similar in form and function.
I agree with Tim, the easiest and most accurate way will be to do it on the lathe.
If I were really hard pressed and very very desperate, since it is brass and soft, chuck it into a cordless drill, have someone hold it on and steady, and with one of the small files cut the groove. This assumes there is enough space at the end to chuck it and cut the groove, you’d want it very close to chuck. If you haven’t cut the rod, chuck it in, then cut the groove and trim the rod as close as you need to your groove. But this is really I’ve got no other way to do this.
Use the Lathe!
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FYI
C clip or what I call a C clip
This is what I’ve called an E clip
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I’ve tried a couple of “at home” methods with not great results. I have done the Lathe class. With the lathe I’ll have to work very close to the chuck so I won’t get deflection. Will the regular carbide cutters cut a groove this narrow or do I need a different tool?
I’m using the e clip.
The cutter will do it, but it will be a V-shaped groove. If the parting tool isn’t too wide it may be able to get in closer with less chance of hitting the chuck. Again, if possible,make the groove about an inch out, slowly ease it in so you don’t exert a lot pressure causing deflection. Then trim back to distance from groove.
Looked up C & E clip as to the technical difference, I confess I was using the term to refer to both (which apparently based on some articles is common). But, I did learn some of the technical differences and when they are used depending on thrust loads - thanks for the prodding me to learn more! While they serve the same purpose it looks to me that a C-clip has more surface engaged in the groove while the E-clip has more on the surface of the shaft. Retaining Rings I confess all the calculations required to determine which is “better” I didn’t bother doing since it involved more parameters than I cared to deal with or capable of.
But for your purposes. it’s how to cut the darn groove.
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For common size clips, you will likely want to either buy a grooving tool, or grind a custom bit out of a HSS blank. None of the bits at DMS are a really good fit.
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He brings up a good point, what is important is the small diameter that the clip engages. If too small, it’s loose and floppy, if too large it may not be past tangent points of diameter and “pop” out.
I’m sure there is an SAE or ISO spec out there giving the tolerance for the specific clips (find I friend that works somewhere they have access to an IHS subscription for specs. 
)
If not high lateral thrust load, maybe consider various Push on rings
I was also going to suggest grinding your own tool out of HSS
I’ve always used the term c clip for both of these too.
Where does one buy a grooving bit? I think grinding a custom bit is beyond my skill set. Someone on the web suggested using an old or broken carbide insert and somehow mounting it sideways to get a thin cut. I’m not sure if that would work.
What I’m working on is a wall mounted art project with several wood gears and ratchets with ball bearings on brass shafts. Right now I’m using rubber O-rings to hold things in place (I have to take it apart a lot) so the push on retainers might work just as well. There really is no force on these things - the clips are just to keep things in place.
It would be nice to figure out how to cut tiny grooves it I needed to. My work on the lathe so far has been just turning to dimension, facing off and drilling holes. I’d like to learn how to do more stuff.
Your best bet would be a appropriately sized cut off tool and the appropriate holder (not sure we have one). Chinese product should be less then $20 for both.
just dropping this in here…
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I’ve cut grooves like this on my wood lathe holding the brass rod in an ER 32 collet chuck I have. The Beal collet chuck doesn’t have anything to hit so it’s very safe in general. Cutters are easy to make. Not sure if we have issues with doing this in the wood shop though.
Any lower end tool holder and insert will work just fine. They actually make inserts specifically for cutting these profiles.
If a push on clip will work, I’d go with that. KISS principle.
You could paint it brass colored and it is symmetrical and you won’t ding up the wood trying to insert clip 1/8" Push on clip $4<
We all seem to be interested, so I see this turning into a class.
I gave that some thought but the problem with push on clips (correct me if I’m wrong) is that they are hard to take off.
I can order this:
http://www.shars.com/products/cutting/tool-bits/1-16-x-1-2-brazed-double-end-t-blade-flat-tipped
if it will fit in the cutoff tool we have.
True about ease of removability, but they are also adjustable, once slot is in, that’s fixed… But your design and aesthetics will dictate what you need.
How wide is clip? 1/16" (.064) seems wide for a clip going on a 1/8" (.125) rod. Clip may wiggle in groove is concern.
@John_Marlow what are your thoughts on this, I consider you the expert on things this size?
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